Yarn carrier

ABSTRACT

A tubular paper yarn carrier for carrying a yarn strand includes a carrier wall defining inner wall surface and outer wall surfaces on opposite sides thereof. One end of the carrier wall defines a top and an opposed end of the carrier wall defines a base. An annular lip is formed on a terminal portion of the base and extends outwardly therefrom for strengthening the base and preventing slippage of the yarn strand off of the base of the carrier. In addition, an annular nose is formed on the inner wall surface proximate the top of the carrier. The annular nose has an outermost edge defining a diameter less than a diameter defined by the inner wall surface for nesting in the base of a like yarn carrier. The lip and nose are integrally formed on the carrier by a rotating tool.

PRIORITY CLAIM

[0001] This application claims priority to U.S. Provisional Application Serial No. 60/312,130, filed Aug. 14, 2001.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

[0002] The invention relates to a yarn carrier for carrying and supporting a yarn strand wound thereon, having an enlarged annular lip on its base end. The invention is directed generally towards yarn carriers that are cylindrical or frusto-conical in shape and which have generally smooth, uninterrupted inner walls. Such yarn carriers are usually referred to as cones or tubes in the textile industry and are made of compressed, impregnated paper fiber. These cones and tubes are typically wound with yarn tails which permit the leading end of yarn on an exhausted cone to be tied to the leading end of yarn on a succeeding full package. The tail is necessary if the transfer from the exhausted to the full package is to take place without dropping needles, which causes a serious defect in the knitted fabric. Consequently, it is an important consideration when winding yarn onto a yarn carrier that such yarn tails do not slip off of the package and become lost.

[0003] Prior art plastic yarn carriers have used a raised rim or roughened portion on the outer surface near the base to frictionally engage the yarn tail to prevent its slippage off of the package. Such a configuration is conducive to yarn carriers made from plastic. However, it would be difficult and impractical to form such a raised, roughened portion on the outer surface of a yarn carrier made from paper fiber which would effectively prevent yarn tail slippage.

[0004] In addition, it is often desirable to stack such yarn carriers on top of each other for storage and transport. By stacking the yarn carriers one on top of each other, a large number of textile packages can be easily stored and transported. Prior art yarn carriers have utilized a bull nose positioned on the inner wall near the top of the carrier and having a diameter slightly smaller relative to the rest of the carrier to facilitate stacking of like carriers. The bull nose positioned on a lower positioned carrier nests against the inner wall of an upper positioned carrier to stabilize the top carrier and prevent it from falling over. In addition, the bull nose adds radial and axial strength to the top of the carrier.

SUMMARY OF THE INVENTION

[0005] Therefore it is an object of the present invention to provide a yarn carrier made of paper fiber having an effective means for preventing slippage of a yarn tail off of the carrier.

[0006] It is another object of the invention to provide a yarn carrier having an annular lip at its base that prevents slipping of the yarn tail off of the carrier by frictionally engaging the yarn tail.

[0007] It is yet another object of the invention to provide a yarn carrier having an enlarged annular lip at its base end to strengthen the base of the package.

[0008] It is yet another object of the invention to provide a yarn carrier that is conducive for stacking on other like yarn carriers.

[0009] It is yet another object of the invention to provide a yarn carrier having a bull nose for stabilizing a like carrier stacked thereon.

[0010] These and other objectives of the present invention are achieved by providing a tubular paper yarn carrier for carrying a yarn strand wound thereon, having a carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof. One end of the carrier wall defines a top and an opposed end of the carrier wall defines a base. An annular lip is formed on a terminal portion of the base and extends outwardly therefrom for strengthening the base and preventing slippage of the yarn strand off of the base of the carrier.

[0011] According to one preferred embodiment of the invention, the inner wall surface defines an inner diameter of the carrier, and the outer wall defines an outer diameter of the carrier. The outer diameter has a value of X and the inner diameter has a value of (0.95)X or less.

[0012] According to another preferred embodiment of the invention, the outer diameter defined by the outer wall surface has a value of X and the annular lip includes an outermost edge defining a diameter having a value of (1.02)X or greater.

[0013] According to yet another preferred embodiment of the invention, an annular nose is formed on the inner wall surface proximate the top of the carrier. The annular nose has an outermost edge defining a diameter less than a diameter defined by the inner wall surface for nesting in the base of a like yarn carrier.

[0014] According to yet another preferred embodiment of the invention, the carrier is cylindrical.

[0015] According to yet another preferred embodiment of the invention, the carrier is frustoconical.

[0016] According to yet another preferred embodiment of the invention, a stackable tubular paper yarn carrier assembly includes a first carrier having a carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof. One end of the carrier wall defines a top and an opposed end of the carrier wall defines a base. An annular lip is formed on a terminal portion of the base and extends outwardly therefrom for strengthening the base and preventing slippage of the yarn strand off of the base of the carrier. An annular nose is formed on the inner wall surface proximate the top. The nose has an innermost edge defining a diameter less than a diameter defined by the inner wall surface for nesting of a second yarn carrier.

[0017] According to yet another preferred embodiment of the invention, a divider is positioned proximate the junction between the first and second carriers for separating yarn strands wound thereon.

[0018] According to yet another preferred embodiment of the invention, a tubular paper yarn carrier for carrying a yarn strand wound thereon includes a carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof, one end of the carrier wall defining a top and an opposed end of the carrier wall defining a base. An annular lip is formed on a terminal portion of the base and extends outwardly therefrom for strengthening the base and preventing slippage of the yarn strand off of the base of the carrier. The annular lip is formed by positioning the terminal portion of the base into a lip shaped void defined by a rotating tool to form the annular lip.

[0019] According to yet another preferred embodiment of the invention, an annular nose is formed on the inner wall surface proximate the top of the carrier by positioning a terminal portion of the top of the carrier in a nose shaped void defined by a second rotating tool to force the terminal portion inward to form the annular nose. The annular nose has an outermost edge defining a diameter less than a diameter defined by the inner wall surface for nesting in the base of a like yarn carrier.

[0020] A preferred method for making a tubular paper yarn carrier according to the invention, includes the steps of providing a tubular paper yarn carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof, one end of the carrier wall defining a top and an opposed end of the carrier wall defining a base. A rotating tool is provided having a void corresponding to a desired shape for a terminal portion of the base. The terminal portion of the base is positioned in the void of the rotating tool to form an integrally formed annular lip extending outwardly from the terminal portion of the base.

[0021] Another preferred method for making a tubular paper yarn carrier having a recessed bull nose according to the invention, includes the steps of providing a tubular paper yarn carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof, one end of the carrier wall defining a top and an opposed end of the carrier wall defining a base. An annular nose is formed on the inner wall surface of the carrier. A rotating tool is provided having a void corresponding to a desired shape for a terminal portion of the top. The terminal portion of the top is positioned in the void of the rotating tool to force the terminal portion inward to form an annular nose on the inner wall surface at the top of the carrier. The annular nose has an outermost edge defining a diameter less than a diameter defined by the inner wall surface.

[0022] Yet another preferred method for making a tubular yarn carrier having a recessed bull nose according to the invention includes the steps of providing a carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof, one end of the carrier wall defining a top and an opposed end of the carrier wall defining a base, and an annular nose formed on the inner wall proximate a terminal portion of the top. A rotating disc is provided having an outer edge for contacting the carrier. A plug is positioned into the top end of the carrier. The rotating disc contacts the terminal portion of the top end of the carrier, and the disc is moved along the top end of the carrier to urge the annular nose inward until the annular nose contacts the plug, whereby the annular nose has an outermost edge defining a diameter less than a diameter defined by the inner wall surface of the carrier.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which:

[0024]FIG. 1 is a perspective view of a prior art yarn carrier;

[0025]FIG. 2 is a perspective view of a yarn carrier according to a preferred embodiment of the invention;

[0026]FIG. 3 is a cross sectional view of the preferred yarn carrier of FIG. 2, as shown along lines 3-3;

[0027]FIG. 4 is an enlarged partial cross sectional view of the preferred yarn carrier of FIG. 2;

[0028]FIG. 5 is a perspective view of a yarn carrier according to another preferred embodiment of the invention;

[0029]FIG. 6 is a perspective view of a yarn carrier according to yet another preferred embodiment of the invention;

[0030]FIG. 7 is a cross sectional view of the preferred yarn carrier of FIG. 6, shown along lines 7-7.

[0031]FIG. 8 is a perspective view of the preferred yarn carrier of FIG. 6, with a like yarn carrier stacked thereon;

[0032]FIG. 9 is a perspective view of the stacked yarn carriers of FIG. 8, with yarn strands wound thereon;

[0033]FIG. 10 is a cross sectional view of the stacked yarn carriers of FIG. 9, shown along lines 9-9.

[0034]FIG. 11A is a cross sectional view illustrating a preferred method for making a yarn carrier having an annular lip according to the invention;

[0035]FIG. 11B is another cross sectional view illustrating the preferred method for making the yarn carrier having an annular lip according to the invention;

[0036]FIG. 11C is yet another cross sectional view illustrating the preferred method for making the yarn carrier having an annular lip according to the invention;

[0037]FIG. 12A is a cross sectional view illustrating a preferred method for making a yarn carrier having a recessed bull nose according to the invention;

[0038]FIG. 12B is another cross sectional view illustrating the preferred method for making the yarn carrier having a recessed bull nose according to the invention shown in FIG. 12A;

[0039]FIG. 12C is yet another cross sectional view illustrating the preferred method for making the yarn carrier having a recessed bull nose according to the invention shown in FIG. 12A;

[0040]FIG. 13A is a cross sectional view illustrating another preferred method for making a yarn carrier having a recessed bull nose according to the invention;

[0041]FIG. 13B is another cross sectional view illustrating the preferred method for making the yarn carrier having a recessed bull nose shown in FIG. 13A; and

[0042]FIG. 13C is yet another cross sectional view illustrating the preferred method for making the yarn carrier having a recessed bull nose shown in FIG. 13A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS AND BEST MODE

[0043] Referring now to the drawings, a prior art yarn carrier is illustrated in FIG. 1, and shown generally at reference numeral 10. The prior art carrier 10 comprises a hollow elongate cylindrical body 11 having a top end 12, a base end 13, an inner wall surface 14, and an outer wall surface 15. A bull nose 17 is formed on the inner wall surface 14 at the top end 12 of the body 11. The bull nose 17 is an annular nodule extending around the entire circumference of the inner wall surface 14 and extends slightly above the body 11. The bull nose 17 is recessed in that its outer edge has a diameter less than the diameter of the inner wall surface 14 of the carrier 10.

[0044] A preferred yarn carrier according to the present invention is illustrated in FIG. 2 and shown generally at reference numeral 20. The yarn carrier 20 comprises a hollow, elongate, cylindrical body 21 made from paper fiber having a top end 22, and a base end 23.

[0045] As shown in FIG. 3, the body 21 comprises an inner wall surface 24, and a parallel outer wall surface 25. An enlarged, annular lip 26 is formed at the base end 23 of the body 21, and extends around the entire circumference of the base end 23, as shown in FIG. 2. The lip 26 can be formed by rolling the edge of base end 23 near the end of the formation process of the yarn carrier 20. A continuous length of yarn is wound on yarn carrier 10 such that it terminates proximate the base end 23. The lip 26 frictionally engages the yarn tail preventing it from slipping off of the yarn carrier 20. In addition, lip 26 adds strength to the yarn carrier 20 by adding extra mass and thickness at the edge of base end 23.

[0046] As shown in FIG. 3, the inner wall surface 24 defines an inner diameter A, and the outer wall surface 25 defines an outer diameter B. Preferably, the inner diameter A is eight percent less than the outer diameter B. The annular lip 26 extends outwardly from the plane of outer wall surface 25. Thus, the outer diameter of lip 26 noted at C is greater than the outer diameter B of the outer wall surface 25. Preferably the outer diameter C of the lip 16 is two percent greater than the outer diameter B of the outer wall surface 25.

[0047] As shown in FIG. 4, the inner wall surface 24 and outer wall surface 25 of the body 21 define a thickness D therebetween. Preferably, the thickness D of the body 21 is 2.2 millimeters. An innermost point and an outermost point of the annular lip 26 define a thickness E therebetween. The height of the annular lip 26 is noted at F. The thickness E of annular lip 26 is preferably at least ten percent greater than the thickness D between inner wall surface 24 and outer wall surface 25, but no more than three times thickness D. In addition, the height F of annular lip 26 is at least one-tenth of thickness D, and no more than three times thickness D.

[0048] Another preferred embodiment according to the present invention is illustrated in FIG. 5 and shown generally at reference numeral 30. Yarn carrier 30 comprises a hollow, elongate, frusto-conical body 31 made from paper fiber having a top end 32, a base end 33, an inner wall surface 34, and an outer wall surface 35. Top end 32 defines a relatively small diameter, and base end 33 defines a relatively large diameter. An annular lip 36 is formed at the base end 33. Yarn carrier 30 is identical in all respects to the yarn carrier 20 described above, except that yarn carrier 30 has a frusto-conical shaped body 31.

[0049] Yet another preferred embodiment of the invention according to the present invention is illustrated in FIG. 6, and shown generally at reference numeral 40. Yarn carrier 40 comprises a hollow, elongate, cylindrical body 41 made from paper fiber having a top end 42, and a base end 43. As can best be seen in FIG. 7, the body 41 comprises an inner wall surface 44, and a parallel outer wall surface 45. An annular lip 46 is formed at the base end 43 of the body 41, and extends around the entire circumference of the base end 43. The yarn carrier 40 is identical to yarn carrier 20 in all respects, except that yarn carrier 40 also includes a recessed bull nose 47 formed on the inner wall surface 44 at the top end 42 of the body 41. The bull nose 47 is an annular nodule extending around the entire circumference of the inner wall surface 44 and extends slightly above the body 41. The outermost edge of the bull nose 47 defines a diameter less than the diameter of the inner wall surface 44. The bull nose 47 adds radial and axial strength to the top end 42 of the carrier 40.

[0050]FIG. 7 shows preferred measurements for yarn carrier 40. Preferably, yarn carrier 40 has an individual height “G” of 170 millimeters, “G” being the distance from the top of the bull nose 47 to the bottom edge of the base 43. The bull nose 47 preferably extends a distance “H” of 7 millimeters from the top of the body 41. The diameter “A” of the inner wall surface 44 is preferably 54 millimeters, and the diameter “K” of the outer wall surface 45 is preferably 58.4 millimeters. The outer diameter C defined by the outer edge of the lip 46 is preferably 59.4 millimeters.

[0051] As shown in FIGS. 8-10, a second yarn carrier 50 can be stacked on top of yarn carrier 40. Yarn carrier 50 is identical to yarn carrier 40 in all respects. Yarn carrier 50 comprises a hollow, elongate, cylindrical body 51 having a top end 52, a base end 53, an inner wall surface 54, and an outer wall surface 55. An annular lip 56 extends outward from the base end 53, and a recessed bull nose 57 at the top end 52.

[0052] The base end 53 of the second yarn carrier 50 is positioned over the top end 42 of the first yarn carrier 40. As shown in FIG. 10, the bull nose 47 of the first yarn carrier 40 nests against the inner wall surface 54 of the second yarn carrier 50 at a contact point “X”, thereby stabilizing the second yarn carrier 50 on the first yarn carrier 40. Nesting of the bull nose 47 against inner wall surface 54 at point “X” prevents the second yarn carrier 50 from falling off of the first yarn carrier 40.

[0053] As shown in FIGS. 9 and 10, the carriers 40, 50 carry yarn strands 48, 58, respectively, shown in phantom. A divider 49 is positioned between the strands 48, 58 at the junction of the carriers 40, 50, separating the two strands 48, 58. The divider 49 preferably has a thickness “I” of 9 millimeters. The thickness “I” of the divider 49 can be substantially less than dividers on other stackable carriers, due to the nesting of the yarn carriers 40, 50. The annular lips 46, 56 prevent slippage of the yarn tails of strands 48, 58, respectively, off of the carriers 40, 50. When stacked on top of each other, carriers 40, 50 preferably have a total height “J” of 333 millimeters. This is due to the fact that the preferred height “H” of the bull nose 47 is 7 millimeters, which is lost in the total height as the carrier 50 is positioned over bull nose 47 of carrier 40.

[0054] Additional yarn carriers can be added to the assembly by positioning bull nose 57 of the second carrier 50 into the base end of a like carrier, or positioning the base end 43 of carrier 40 over the bull nose of a like carrier. Preferably, up to seven carriers are stacked on top of each other in this fashion. An assembly of carriers can be formed in which a plurality of carriers are positioned on a pallet having holes for receiving the carriers. A second pallet with corresponding holes is placed on top of the carriers and a second layer of carriers are stacked on the first layer of carriers. This process can be repeated any desired number of times, and preferably so there are seven layers of carriers. Preferably, each pallet supports twenty carriers, for a total of 140 carriers contained in a seven layer assembly.

[0055] A preferred method for making carrier 40 is illustrated in FIGS. 11A-C and 12A-12C. FIGS. 11A-11C illustrate a preferred method for forming the annular lip 46 at the base end 43 of the carrier 40. As shown in FIG. 11A, a rotating tool 60 is provided having a void 61 for receiving the base end 43 of carrier 40. The void 61 is shaped to force the base end 43 outward when the tool is rotated counterclockwise, to form the annular lip 46, as shown in FIGS. 11B and 11C.

[0056] FIGS. 12A-12C illustrate a preferred method for forming the recessed bull nose 47. As shown in FIG. 12A, another rotating tool 70 has a void 71 shaped to receive the top end 42 of the carrier 40 having a conventional bull nose 42A preformed on the inner wall surface 44 of the carrier 40. The void 71 is shaped so that it moves the top end 42 inward to form the recessed bull nose 47 when the tool is rotated clockwise, as shown in FIGS. 12B and 12C.

[0057] FIGS. 13A-13C illustrate another preferred method for forming the recessed bull nose 47. As shown in FIG. 13A, a disc 80 is mounted on a shaft 81 and has two bearings 82 for rotating the outer edge 83 of the disc 80 about the shaft 81. A plug 84 is inserted into the top end 42 of the carrier 40. The carrier has a pre-formed conventional bull nose 42A. The diameter of the plug 84 corresponds to the desired diameter of the outermost edge of the bull nose 47. As shown in FIGS. 13B and 13C, the disc 80 is lowered into contact with the carrier 40. The disc 80 rotates and moves about the top end 42 of the carrier 40, forcing the top end 42 inward to form the recessed bull nose 47. Inward movement of the top end 42 of the carrier is stopped by engagement with the plug 84 positioned inside. As such, the amount of recess in bull nose 47 relative to the rest of the carrier 40 can be varied by altering the diameter of the plug 84 inserted into the carrier 40.

[0058] A yarn carrier and a method of making same is disclosed above. Various embodiments of the invention can be made without departing from its scope. Furthermore, the foregoing description of the preferred embodiments of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the following claims. 

We claim:
 1. A tubular paper yarn carrier for carrying a yarn strand wound thereon, comprising: (a) a carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof, one end of the carrier wall defining a top and an opposed end of the carrier wall defining a base; and (b) an annular lip formed on a terminal portion of the base and extending outwardly therefrom for strengthening the base and preventing slippage of the yarn strand off of the base of the carrier.
 2. A yarn carrier according to claim 1, wherein said inner wall surface defines an inner diameter of the carrier, and said outer wall defines an outer diameter of the carrier, wherein said outer diameter has a value of X and said inner diameter has a value of (0.95)X or less.
 3. A yarn carrier according to claim 2, wherein said outer diameter defined by said outer wall surface has a value of X and said annular lip includes an outermost edge defining a diameter having a value of (1.02)X or greater.
 4. A yarn carrier according to claim 1, further comprising an annular nose formed on the inner wall surface proximate the top of the carrier, said annular nose having an outermost edge defining a diameter less than a diameter defined by the inner wall surface for nesting in the base of a like yarn carrier.
 5. A yarn carrier according to claim 1, wherein said carrier is cylindrical.
 6. A yarn carrier according to claim 1, wherein said carrier is frusto-conical.
 7. A stackable tubular paper yarn carrier assembly comprising a first carrier comprising: (a) a carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof, one end of the carrier wall defining a top and an opposed end of the carrier wall defining a base; (b) an annular lip formed on a terminal portion of the base and extending outwardly therefrom for strengthening the base and preventing slippage of the yarn strand off of the base of the carrier; and (c) an annular nose formed on the inner wall surface proximate the top, said nose having an innermost edge defining a diameter less than a diameter defined by the inner wall surface for nesting of a second yarn carrier.
 8. A stackable yarn carrier assembly according to claim 7, further comprising a divider positioned proximate the junction between said first and second carriers for separating yarn strands wound thereon.
 9. A tubular paper yarn carrier for carrying a yarn strand wound thereon, comprising: (a) a carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof, one end of the carrier wall defining a top and an opposed end of the carrier wall defining a base; and (b) an annular lip formed on a terminal portion of the base and extending outwardly therefrom for strengthening the base and preventing slippage of the yarn strand off of the base of the carrier, wherein said annular lip is formed by positioning the terminal portion of the base into a lip shaped void defined by a rotating tool to form said annular lip.
 10. A tubular paper yarn carrier according to claim 9, further comprising an annular nose formed on the inner wall surface proximate the top of the carrier by positioning a terminal portion of the top of the carrier in a nose shaped void defined by a second rotating tool to force the terminal portion inward to form said annular nose having an outermost edge defining a diameter less than a diameter defined by the inner wall surface for nesting in the base of a like yarn carrier.
 11. A method for making a tubular paper yarn carrier having an annular lip for preventing slippage of a yarn strand wound thereon, comprising the steps of: (a) providing a tubular paper yarn carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof, one end of the carrier wall defining a top and an opposed end of the carrier wall defining a base; (b) providing a rotating tool having a void corresponding to a desired shape for a terminal portion of said base; (c) positioning the terminal portion of said base in the void of the rotating tool to form an integrally formed annular lip extending outwardly from the terminal portion of the base.
 12. A method for making a tubular yarn carrier including an annular nose having an outermost edge defining a diameter less than a diameter defined by an inner wall surface of the carrier for nesting of a like yarn carrier, comprising the steps of: (a) providing a carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof, one end of the carrier wall defining a top and an opposed end of the carrier wall defining a base, and an annular nose formed on the inner wall proximate a terminal portion of the top; (b) providing a rotating tool having a void corresponding to a desired shape for the terminal portion of the top; (c) positioning the terminal portion of the top in the void of the rotating tool to force the terminal portion inward to form an annular nose having an outermost edge defining a diameter less than a diameter defined by the inner wall surface.
 13. A method for making a tubular yarn carrier including an annular nose having an outermost edge defining a diameter less than a diameter defined by an inner wall surface of the carrier for nesting of a like yarn carrier, comprising the steps of: (a) providing a carrier wall defining an inner wall surface and an outer wall surface on opposite sides thereof, one end of the carrier wall defining a top and an opposed end of the carrier wall defining a base, and an annular nose formed on the inner wall proximate a terminal portion of the top; (b) providing a rotating disc having an outer edge for contacting the carrier; (c) positioning a plug into the top end of the carrier; (d) contacting the terminal portion of the top end of the carrier with the rotating disc and moving the disc along the top end of the carrier to urge the annular nose inward until the annular nose contacts the plug, whereby the annular nose has an outermost edge defining a diameter less than a diameter defined by the inner wall surface of the carrier.
 14. A method for making a tubular yarn carrier according to claim 13, wherein the plug defines a predetermined diameter corresponding to a predetermined diameter of the outermost edge of the annular nose. 